kelsey



May 24, 1927. Re.' 16,638

. W. KELSEY MATTRESS AND METHOD 0F MAKING THE SAME origini Filed April 11, i9z4 2 sheets-sheet 1 y ml, ml: I fla, n (MMI/lh 24 1927. May w. H. Kr-:LsEY

MATTRESS AND METHOD OF MAKING THE SAME original Filed Apri 11`. 1924 2 Sheets-Sheet 2 Reissued May 24, 1927.

Y'wnnmn nilAnnIsoN' meer,

or xANsAs srry, 'Mrssoonr `latarcrauizss Nn ymirra-tcm) loF `Jamzine THE f originar No. 1,559,708, dated November a, lezarseriaina 'liospmlieu April .11, .1921. Application for reissue filed October 11, 19.26. Serial No. 141,007,

The invention relates to mattresses and hasfor its objectto-provide certain new and useful improvementstherein due to the practice of a nen7 `'method of Construction` whereby a mattress is provided which is "of a stretchless nature and Vwhich will not lose its r shape.

In the manufacturev `of.I'nattresses one .of the greatest diiiiculties liefs in the arranging and Joining of the ticking thereof with relation to the boxing in afmann'er for reventing great bulging Vof sides and en s intermediately of the corners. lThis objectionable feat-ure 1s commonly present in mattresses now vmanufactured,and when such mattresses stretch'and expand. they become unsightly andI interfere withthe desired neat 'appea ance of. beds upon which'they are used; n y Therefore, in .its more detailednature the invention has for its object to provide a st-retchless mattress structure and the same is vproduced by the peculiar. method of cut.- ting and join'in andar-rangement of the ticking with theroxinof in amanner whereby .stretching andthe oss Vof shape incident thereto are avoided.

lViththe aboveA and 'other objects in View the invention further resides in those novel details of construction, rcombination and arrangement 'of parts, all of which'will be rs't fully described, then be particularly pointed 'out the appended claims, reference being had to the accompanying drawings, `in which:-. I

`-Figure 1 is a perspective View of the mattress boxing. Y

lFigure 2`vis a perspective view of one of theticking sheets. j Y Figure 3 is a perspective view of the ticking sheet after the `'same has been sewn.

Figure 4 is a'detail crossl section of one corner of the mattress formed by the meeting portions of the 'ticking and boxing showing the. manner in which the same 'are sewn to ether. v

igure 5 is a detail Icross section similar to Figure 4 showing the mattress corner after the same is complet-ed. v Figure 6 is a detail diagrammatic Aperspective view illustrating `the tucking step of the construction method.

Figure `7 is ya` detail diagrammatic longitudinal 'section illustrating the manner of Iforming the edge rolls. y v y Figures 8 and 9 are diagrammatic plan views illustrating completed mattresses embodying' my invention and common methods vrespeotlvely, after undergoing a period of use. i Figure. 1,0 is a detail perspective view showing a completed mattress. y

`Figures 11 and 12 arediagrammatic perspective views illustratingl the boxing and ticking sheetfeatures of a modified form vof the invent-ion respectively.`

lIn constructing the .mattress in accordancewith my invention I utilize jan open substantially rectangular boxing 1 formed 'from a strip ofsuitable material of suicient length to have the ends thereof sew-ed .together for providing 'said boxing in the manner clearly i indicated in Figure 1 of the drawings.

For cooperating with the boxing in forming the mattress casing, top and bottom ticking sheets 2 are provided, and, in the preferred form of the invention illustrated `in Figures 41 t'o7 inclusive of the drawingsand in Figures 8 and 10, each of Asaid ticking sheets isconstructed in the manner clearly illust-rated `in .Figure 2. i The ticking Sheets are so formed by utilizing yareotan lar sheet of the desired material, thegsai rectangle being of dimensions slightly. in excess ofthe dimensions of the boxing. For example, if theboxing dimensions cover an areaof four feet six inches in width by six yfeet three inches in length the corresponding ticking dimensions would be in the vn'eighborliood of live feet one inch in width by seven feet two inches in length, thusall'owing a surplus of length and width at each end'and side for purposes later to be explained. Afterv the rectangularsheet has'thus been formed a portion of each side thereof .is out-away on a curved line, from points adjacent the corners thereof, in a manner indicated by the numeral 3 on Figure Zand elsewhere in the. drawings. Portions 'of the ticking l are cut out in a manner for providing vtransverse curved slits 4, extending substantially parallel to the stripes 14 which in 'ticking always run with the weave,A

that is, with the warp threads 15.r lThe ends 5 of the ticking are not cut but remain strai ht as originally, see Figure 2. y

A er'the transverse slits 4 have been cut as indicated in Figure 2 of the drawings the said slits are sewed together to form seams somewhat inthe manner illustrated by 'the numeral 6 on'Figure 3 of the dra-wings. The

sewing together at 6 of the transverse curved slits 4 effects a pulling in of the formerly straight edges 5 so as to cause them to take a curved shape indicated by the numeral 7 on Figure 3, and proportionately corresponding with the curved .sides formed by cutting as indicated at 3. It should be understood that both the top and bottom sheets, which cooperate with the boxing 1, are treated as just -described in providing the casing for the improved mattress structure which is the subject of my invention.

The edges of the top and bottom ticking sheets, formed as above described` are next tucked and sewed to the edges of the boxing l in the manner indicated by the numeral 8 in Figures 4 and 6 of the drawings, and with the seams 6 and stripes 14, andhence the direction of the weave, extending transversely of the mattress; it will be understood, of course, that a portion of one end will be allowed to remain open to permit the proper stuffing of the mattress with any suitable stuffing material indicated by the numeral .9, after which that end will of course be tuckedv and sewed as were all the remaining edges of the said parts, thus providing what might be termed an over-stuffed mattress having surplus dimensions and not drawn in to its final shape but somewhat oversized as indicated in Figure 4 of the drawings. See Figure 6 for the tucking and sewing feature.

In carrying out the next step in completing the mattress structure the edge materials are taken up along the joining edges of said ticking and the boxing by the heavy thread 10, sewed in zigzag fashion, across the said edge materials, especially the ticking edge material, in a manner for providing the roll 11 which exten-ds around the whole mattress structure at all of the edges thereof. The manner of forming this roll is clearly illustrated in Figure 5 ofl the drawings. The manner of sewing the thread in forming this roll is clearly illustrated in Figure 7 of the drawings, while Figure 10 illustrates the appearance of the completed product.

After the roll 11 has been formed as just described, the only remaining step necessary to complete the mattress and thus form the structure illustrated in Figure 10 is the sewing of the usual tufts 12 which are suitably sewed and spaced in the manner common in mattress structure and for the purpose of confining the stuing and providing the desired uniformity of top and bottom mattress surfaces. The tufts 12 at that part of the mattress at which the seams 6 occur may be positioned along said seams, and in this manner the said seams are edectively hidden.v

I-n the manufacture of mattresses much difficulty is occasioned in trying to prevent the mattress from bulging and losing its desired shape,` the common fault of such mattresses being indicated diagrammatically in Figure 9. This is due to the fact that the parts of the mattress are merely cut on standard dimensions and without reference to the ticking weave, such that when assembled and the casing to be formed stuffed, the mattress will expand beyond the desired dimensions and, particularly after some use, will distend itself and stretch so as to cause the boxing thereof to bulge out,

By reason of providing specially constructed ticking sheets of the shape illustrated in Figure 3 of the drawings, the mattress casing is provided which, when stuffed, l

can expand approximately to a predetermined desired dimension asl represented in Figure 8, and with the weave or warp threads running transversely it cannot extend itself materially beyond that dimension and therefore will hold its shape more efficiently. v

It will be observed from Figures 11 and 12 of the drawings that the same broad purpose of my invention may be accomplished by providing the usual boxing illustrated in Figure 11.and cutting the ticking sheets 2 cooperative therewith, as at 3 and 13, to immediately form the said ticking to the ultimate shape desired without utilization of the transverse slit feature, but nevertheless securing said sheets'to the boxing with the weave or warp or most tautly woven threads 15 extending transversely of the mattress, as before. This simpler method may be found practical in the construction of some cheaper `types of mattresses, especially those in which plain unstriped material is used. However, I prefer to construct the mattress in accordance with the illustration of Figures 1 to 7, ,because by so- .doing a more perfect finished product is produced than would be possible by merely cutting the edges at 3 and 13. By using the transverse slit feature undue distortion of the stripes is prevented, especially where the stripes of the material are positioned to run transversely of the mattress, in which event it would be obvious that to cut out the material to form the curves 7, instead of forming the same by seaming the slits 4, as at 6, ywould result in the cutting away of a portion of the material so that when the curves 7 would be sewn to the boxing, the distortion would be readily apparent. However, by drawingin the original straight edges 5 by the seams 6 and thus forming the curves 7, the seams 6 being usually positioned to avoid the stripes, all distorted appearance of the 'mattress is prevented. In either form of the invention, I find that by securing the ticking sheets to the boxing in such away that the weave or warp or most tautly ywoven threads of the tickingY sheets run transversely or crosswise of the matregata tess, the sheets will, notstretch,appiteci'afblfy'v crosswise, and hencecrj'swis stretchingof di@ :maitres:- iosi Yimamic/ally eliminated- 'By reasen of tuc'lzingl` thejedgeslofthe ticking'sheets andv sewing them iri th-iscoii'- ditiont'the adjacent boxing edgesgthejsurplus of. material edge length, made' neces-- sary by thy provision' of the Y eurvesatf ends "and" sides, iseifec'tively drawn up -so `asf't pull the lmaterial perfect-ly even around 'the whole vof the mattress4 and thus provide a funiform', and neat' ay paring" structure.-l

described without departing from 'my 'j forming the e geA rolls 1'1 the heat/' y thread lOis' se'wefd'fzigzagl thif'ough 'the ,bbxing andtickfing' materialefdvjesthe ta'cisvof the thread at ,one side lifting/r1l shrtwhfile' thosebffthe other'si'de arelatively long, thus .effectively ,accomplislliiigl .the.roll.forming functionv and effecting a thread economy. See Figure 7. Y 5

In carrying out the preferred form of my invention, the steps of the method are in sequence as illustrated in Figures 1 to 5 inclusie of the drawings, see also Figures 6 and I have found that the particular tucking feature here vdisclosed is far superior to pleating or other methods since by the use of such other methods the finished mattress structure is not as smooth and even as the structure made possible by the utilization of this feature of my invention. Y

From the foregoing description, taken in connection with the accompanyingV dra-wings, it is thought that the noveldetails'of construction, the manner of carrying'out the invention and the advantages thereof will be readily apparent to those skilled inthe art.

Various slight changes might be made in the general form and arrangement of parts 1nvention, and hence I do not ilimit myself to the precise details set forthbut consider myself at liberty to make such changes and alterations las fairly fall within the spirit and scope of the appended claims.

What I claim is: y

1. In a mattress, a substantially rect-angular boxing, ticking adapted to be secured to i the boxing to form the mattress casing, and

stuing for filling the mattress casing, the

said ticking havingv curves at thesides and ends thereof. y y

2. In a mattress, a substantially rectangular boxing, ticking adapted to be secured to the boxing to form the mattress casing,` land stuffing for filling the mattress casing,

the said ticking being shaped on a curve at` each ofthe sides and ends, which curves extendA inwardly from pointsV adjacent each corner. Y n

3. Ina mattress, a substantially rectangular boxing, ticking adapted to be secured to the boxing to form the mattress casing, stuifing for filling the mattress casing,'the Said 'edges thereof. Y y

,l 4. in, ,a mattress a Substantially maan-gular boxing-tifcking adaptedA to be" secured' to Vtickiiig'""bein'gof vadim'eiision in excess of the dimension ofthe boxing' and" being formed with: reduced' side' afdfendl portions and h'avdges tucked, and e'dge vro'lls surf roundingr th mattress at the edges thereof,

and fornie'dlby'sevting' through the ticking and. boxing material adjacent lthe joined edges thereof and formed by sewing through fthe ticking and boxing material adjacent the joined edges thereof.

5. .In a mattress, a substantially rectangular boxing, ticking adapted to be secured-to the boxing to formthe mattress casing, and E stuffing for filling the mattress casing, the said ticking having concaved sides and seams formed transversely thereof to form concaved ends.

6. In a mattress, a substantially rectangular boxing, ticking adapted tobe secured to the boxing to form the mattress casing, and stuffing for lilling the mattress casing, vthe said ticking being of adimension in excess of the boxing and being formed with con,

caved sides and ends and having the said concaved Vedges tucked, Vand edge rolls surrounding the mattress at the edges thereof and vformed by sewing through the ticking and boxing material adjacent the joined edges thereof.

7 In a mattress, a substantially,rectangular boxing, ticking adapted to be secured 'to the boxing to form the mattress casing, and stuffing for-filling the mattress casing, the said ticking having conca'ved sides and seams formed transversely thereof to form concaved ends, the said concaved ends and sides being tucked, and being of dimensions in excess of those of the boxing to permit the provision of the ticking concave feature, and edge rolls surrounding the mattress at the edges thereof and formed by sewing through the ticking and boxing material adjacent the joined vedges thereof.

, l8. In a mattress, a substantially rectangular boxing, ticking adapted `to be secured to the boxing to form the mattress casing, and stufiing for filling the mattress casing, the said ticking having concaved sides and seams formed transversely thereof to form concaved ends, and tufts sewed to and through the ticking and stulng to shape the mattress top and bottom, those of the tufts adjacent the transverse seams being posi.-

tioned along the said seams to render the said seams inconspicuous.

9. In a. mattress, a. substantially rectangular boxing, ticking adapted to be secured to the boxing to form the mattress casing, and stuffing for illing the mattress casing, the said ticking having vconcaved sides and seams formed transversely thereof to form concaved ends, the said concaved ends and sides being tucked, and being of dimensions in excess of those of the boxing no permit the provision of the ticking concave feature, edge rolls surrounding the mattress at the edges thereof and formed by sewing through the ticking and boxing material adjacent the joined edges thereof, and tufts seWed to and through the ticking and stutiing to shape the mattress top and bottom, those of the tufts adjacent the transverse seams being positioned along the said seams to render the said seams inconspicuous.

10. In a mattress, a substantially rectangular boxing, striped ticking adapt-ed to be secured to the boxing to form the mattress casing with the Weave of the ticking running crosswise of the mattress, andstung for filling thevmattress casing, the said ticking having curves at the sides and ends thereof.

11. In a mattress, a substantially rectangular boxing, ticking adapted to be secured to the boxing to form a mattress casing, said ticking having the Weave running crosswise of the mattress, and stufing for filling the casing, said ticking having concave sides and seams formed transversely thereof to constitute curved ends.-

WALTER HARRISON KELSEY.k 

